Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G79/00—Macromolecular compounds obtained by reactions forming a linkage containing atoms other than silicon, sulfur, nitrogen, oxygen, and carbon with or without the latter elements in the main chain of the macromolecule
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07F—ACYCLIC, CARBOCYCLIC OR HETEROCYCLIC COMPOUNDS CONTAINING ELEMENTS OTHER THAN CARBON, HYDROGEN, HALOGEN, OXYGEN, NITROGEN, SULFUR, SELENIUM OR TELLURIUM
  • C07F5/00—Compounds containing elements of Groups 3 or 13 of the Periodic Table
  • C07F5/06—Aluminium compounds
  • C07F5/061—Aluminium compounds with C-aluminium linkage
  • C07F5/066—Aluminium compounds with C-aluminium linkage compounds with Al linked to an element other than Al, C, H or halogen (this includes Al-cyanide linkage)
  • C07F5/068—Aluminium compounds with C-aluminium linkage compounds with Al linked to an element other than Al, C, H or halogen (this includes Al-cyanide linkage) preparation of alum(in)oxanes
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07F—ACYCLIC, CARBOCYCLIC OR HETEROCYCLIC COMPOUNDS CONTAINING ELEMENTS OTHER THAN CARBON, HYDROGEN, HALOGEN, OXYGEN, NITROGEN, SULFUR, SELENIUM OR TELLURIUM
  • C07F7/00—Compounds containing elements of Groups 4 or 14 of the Periodic Table
  • C07F7/02—Silicon compounds
  • C07F7/08—Compounds having one or more C—Si linkages
  • C07F7/0834—Compounds having one or more O-Si linkage
  • C07F7/0838—Compounds with one or more Si-O-Si sequences
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
  • C08F10/00—Homopolymers and copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G77/00—Macromolecular compounds obtained by reactions forming a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon in the main chain of the macromolecule
  • C08G77/48—Macromolecular compounds obtained by reactions forming a linkage containing silicon with or without sulfur, nitrogen, oxygen or carbon in the main chain of the macromolecule in which at least two but not all the silicon atoms are connected by linkages other than oxygen atoms
  • C08G77/58—Metal-containing linkages

Definitions

• This process relates generally to soluble aluminoxane derivatives and more particularly to siloxy-aluminoxane compositions obtained by the reaction of alkyldisiloxanes and aluminoxanes which, in the presence of metallocenes, form catalytically active compositions for olefin polymerization.
• U.S. Patent No. 3,740,384 discloses that the addition of dihydroxysiloxane to non-metallocene organozirconium catalyst systems in the absence of aluminoxanes gave improved catalyst activity in olefin polymerization.
• U.S. Patent No. 4,945,076 describes the improved activity in olefin polymerization which is obtained by the addition of dihydroxysiloxane to a catalyst system consisting of a metallocene and an aluminoxane. The resulting ethylene polymer is said to have acquired a lower melt flow rate (MFR) than those produced without the silicon compound.
• MFR melt flow rate
• alkoxy-silanes having Si-O-C bonds silicon diols having Si-OH bonds and dihydroxysiloxanes having both the Si-O-Si and Si-OH bonds.
• the reagents used in the present invention namely alkyldisiloxanes, have only the Si-O-Si bonds.
• the chemical reactivity of the alkyldisiloxanes is significantly different from those of the silanols, silyl ethers, silyl esters and hydroxy disiloxanes ( 1 . Comprehensive Organometallic Chemistry , Vol. 2, Chap. 9; Pergamon Press, 1982: 2 . Comprehensive Organic Chemistry , Vol. 3, Chap. 13 Pergamon Press N.Y.
• aluminoxanes will react with alkyldisiloxanes to form novel, soluble siloxy-aluminum compounds which, in combination with metallocenes, provide olefin polymerization catalysts having very high activity.
• siloxy-aluminoxane composition which is the reaction product of an alkyldisiloxane and an aluminoxane where the molar portions of aluminum to alkyldisiloxane are from 1:1 to 50:1.
• an olefin polymerization catalyst comprising a metallocene of a transition metal and a siloxy-aluminoxane composition which is the reaction product of an alkyldisiloxane and an aluminoxane where the molar portions of aluminum to alkyldisiloxane are from 1:1 to 50:1.
• Preferred aluminoxanes for use in making the siloxy-aluminoxane compounds are hydrocarbylaluminoxanes.
• Hydrocarbylaluminoxanes may exist in the form of linear or cyclic polymers with the simplest compounds being a tetraalkylaluminoxane such as tetramethylaluminoxane, (CH3)2AlOAl(CH3)2, or tetraethylaluminoxane, (C2H5)2AlOAl(C2H5)2.
• the compounds preferred for use in olefin polymerization catalysts usually contain 4 to 20 of the repeating units: where R is C1-C10 alkyl and especially preferred are methylaluminoxanes (MAO).
• the methylaluminoxanes can contain some higher alkyl groups to improve their solubility. Such modified methylaluminoxanes are described, for example, in U.S. Patent No. 5,157,008.
• the aluminoxanes can be prepared as known in the art by the partial hydrolysis of trialkylaluminum compounds.
• the trialkylaluminoxane compounds can be hydrolyzed by adding either free water or water containing solids, which can be either hydrates or porous materials which have absorbed water. Because it is difficult to control the reaction by adding water per se, even with vigorous agitation of the mixture, the free water is preferably added in the form of a solution or a dispersion in an organic solvent.
• Suitable hydrates include salt hydrates such as, for example, CuSO4 ⁇ 5H2O, Al2(SO4)3 ⁇ 18H2O, FeSO4 ⁇ 7H2O, AlCl3 ⁇ 6H2O, Al(NO3)3 ⁇ 9H2O, MgSO4 ⁇ 7H2O, ZnSO4 ⁇ 7H2O, Na2SO4 ⁇ 10H2O, Na3PO4 ⁇ 12H2O, LiBr ⁇ 2H2O, LiCl ⁇ 1H2O, LiI ⁇ 2H2O, LiI ⁇ 3H2O, KF ⁇ 2H2O, NaBr ⁇ 2H2O and the like and alkali or alkaline earth metal hydroxides such as, for example, NaOH ⁇ H2O, NaOH ⁇ 2H2O, Ba(OH)2 ⁇ 8H2O, KOH ⁇ 2H2O, CsOH ⁇ 1H2O, LiOH ⁇ 1H2O and the like.
• salt hydrates such as, for example, CuSO4 ⁇ 5H2O,
• the mole ratios of free water or water in the hydrate to total alkyl aluminum compounds in the mixture can vary widely, such as for example from 2:1 to 1:4 with ratios of from 4:3 to 1:3.5 being preferred.
• methylaluminoxanes contain varying amounts, of from about 5 to 35 mole percent, of the aluminum value as unreacted trimethyl-aluminum.
• the alkyldisiloxanes for use in the invention have alkyl groups which preferably contain from 1 to 20 carbon atoms.
• the alkyldisiloxanes contain the Si-O-Si bond and are substantially free of Si-OH or Si-O-C bonds.
• the alkyl disiloxanes can contain mixed alkyl groups.
• Non-limiting examples of alkyldisiloxanes include hexamethyldisiloxane, hexaethyldisiloxane, tetramethyldisiloxane, and the like.
• the siloxy-aluminoxane compositions can be prepared by reacting the aluminoxane and alkyldisiloxane in an organic solvent medium in molar portions of aluminum to alkyldisiloxane of from 1:1 to 50:1. Mixtures of aluminoxanes and/or alkyldisiloxanes can be used in forming the compositions. Any inert organic solvent can be used as the reaction medium.
• Non-limiting examples of solvents include aliphatic hydrocarbons such as pentane, isopentane, hexane, cyclohexane, heptane, octane, decane, dodecane, hexadecane, octadecane and the like with those having carbon numbers of 5 to 10 being preferred and aromatic hydrocarbons such as benzene, toluene, xylene, cumene and the like with those having carbon numbers of 6 to 20 being preferred.
• aromatic hydrocarbons such as benzene, toluene, xylene, cumene and the like with those having carbon numbers of 6 to 20 being preferred.
• amounts of solvent to provide a total concentration of reactants of from 10 to 30 wt. percent are used.
• Preferred reaction temperatures range from about 25 to 90°C.
• the siloxy-aluminoxane compounds can be used in combination with metallocenes to provide olefin polymerization catalysts.
• metallocenes are well known in the art and non-limiting examples include the metallocenes described in published European patent application No. 0 129,368 and U.S. Patent Nos. 5,017,714 and 5,026,798, whose teachings with respect to such metallocenes are incorporated herein by reference.
• metallocenes are bis-(cyclopentadienyl)-zirconium dimethyl, bis-(cyclpentadienyl)-zirconium dichloride, bis-(cyclopentadienyl)-monomethyl-monochloride, bis-(cyclpentadienyl)-titanium dichloride, bis-(cyclopentadienyl)-titanium difluoride, cyclopentadienyl-zirconium tri-(2-ethylhexanoate), bis-cyclopentadienyl)-zirconium hydrogen chloride, bis-(cyclopentadienyl)hafnium dichloride and the like.
• the catalyst components are used in proportions to provide mole ratios of transition metal atom to aluminum atom of from 0.0002:1 to 0.2:1 and preferably 0.0005:1 to 0.02:1.
• the catalyst components can be used in solution or deposited on a solid support.
• the solid support can be any particulate solid, and particularly porous supports such as talc or inorganic oxides, or resinous support material such as polyolefins.
• the support material is an inorganic oxide in finely divided form.
• Suitable inorganic oxide support materials which are desirably employed include Group IIA, IIIA, IVA or IVB metal oxides such as silica, alumina, silica-alumina and mixtures thereof.
• Other inorganic oxides that may be employed either alone or in combination with the silica, alumina or silica-alumina are magnesia, titania, zirconia, and the like.
• Other suitable support materials are finely divided polyolefins such as finely divided polyethylene.
• the catalysts are effective to produce olefin polymers and especially ethylene polymers and ethylene/ ⁇ -olefin copolymers.
• olefins that can be polymerised in the presence of the catalysts of the invention include ⁇ -olefins having 2 to 20 carbon atoms such as ethylene, propylene, 1-butene, 1-hexene, 4-methyl-1-pentene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, and 1-octadecene.
• Polymerization of ethylene or copolymerization with ethylene and an ⁇ -olefin having 3 to 10 carbon atoms is preferable.
• Such polymerizations may be performed in either the gas or liquid phase (e.g. in a solvent, such as toluene, or in a diluent, such as heptane).
• the polymerization can be conducted at conventional temperatures (e.g., 0° to 120°C.) and pressures (e.g., ambient to 50 kg/cm2) using conventional procedures as to molecular weight regulations and the like.
• H-1 NMR data showed more sharp peaks overlapping the usual MAO broad peak in the aluminum alkyl region, than was seen in the alkane product.
• the starting material in the above described reactions was solid MAO. This was obtained by removal of toluene from the MAO solution via vacuum distillation. For commercial purposes, it is desirable to avoid extra processing requirements.
• the following examples describe the formation of siloxy-MAO compositions directly from the initial toluene solution of MAO.
• TMA trimethyl-aluminum
• Ethylene polymerization was conducted in a Parr reactor (600 mL) equipped with a cooling coil, magnetic stirrer, pressure gauge and a gas inlet.
• the catalyst system, siloxy-MAO and zirconocene dichloride, are dissolved in toluene (300 mL).
• the loading was done in a dry-box after which the reactor was assembled in a well vented hood. Ethylene was passed into the reactor at 60 psi for 10 minutes while the temperature was maintained at about 90°C.
• the reactor contents were poured into a beaker where an equal volume of methanol was added to destroy the catalyst system.
• the polyethylene was collected by filtration and then dried in a vacuum oven.
• Table 1 shows that no significant additional activity was gained as the molar ratio of HMDS was increased. However, the data in this table show a notable increase (about 50%) in the activity of the siloxy-MAO derivatives as compared to the regular MAO under similar conditions.

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• Transition And Organic Metals Composition Catalysts For Addition Polymerization (AREA)
• Addition Polymer Or Copolymer, Post-Treatments, Or Chemical Modifications (AREA)

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• 1993
  • 1993-02-01 US US08/011,599 patent/US5391529A/en not_active Expired - Lifetime
• 1994
  • 1994-01-06 CA CA002112965A patent/CA2112965C/fr not_active Expired - Lifetime
  • 1994-01-27 JP JP02361494A patent/JP3673290B2/ja not_active Expired - Lifetime
  • 1994-01-31 DE DE69423670T patent/DE69423670T2/de not_active Expired - Lifetime
  • 1994-01-31 EP EP94101418A patent/EP0621279B1/fr not_active Expired - Lifetime

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